Subsequently, colors are applied one by one to the shirt, which is then dried and cured to complete your final product. Find out what they are and if they could be of value to your company by downloading the Gherzi white paper: hbspt.cta._relativeUrls=true;hbspt.cta.load(2131785, '83e2775e-6cd7-4e76-8446-f17ac7af98af', {}); Categories: Learn more about the difference between digital textile printing and rotary screen printing when it comes to fast-fashion manufacturing in the video below: Did your cost comparison show that digital textile printing could be of value for your printing company? This is probably the hardest question to answer. For example, when you do a 4-color printing job, you have 4 plates. On average, plan on spending around $8 to $15 per t-shirt. One stencil for each color of a design is created by using ultraviolet light to harden a substance applied to the mesh that prevents the passage of ink. In an independent study conducted by Gherzi (www.gherzi.com) an estimate was made about the break-even point between rotary and digital. For that reason, digital textile printing can be a more cost-friendly option for printing companies that work with very colorful designs and many color ways per design. With most companies, the more you purchase at once, the lower the “per item” rate will go. However, it produces high-quality results that have remained extremely popular with consumers for decades. You need a t-shirt printing system that matches both your dreams AND your budget. Age of screen printing process Screen printing’s original roots go back to Egyptian times with stencilling and then later in China (900 A.D.) when they first forced ink … Print is not as durable as screen prints; Fewer options of printable fabrics; Printing in bulk does not offer cost reductions because of fixed prices; Digital printing, while more limited than screen printing in some ways, is a fine choice for finely detailed images or designs that feature complex gradients. Each one of these choices in technology provides different opportunities for a business to grow. Screen printing is the classic, tried-and-true method of pushing ink through a woven mesh stencil onto the fabric. As pointed out before, it heavily depends on the number of colors you want to print, the number of color ways and the number of printed meters per color way. Screen printing also has the advantage of a large selection of different types of inks that are all considerably less expensive per garment than Digital Printing inks. Changing colors to make another colorway can happen instantly, where in conventional you need to clean out the printing paste in each screen and replace it for the new color. On top of that, digital textile printing helps printers to reduce water consumption by 60%, chemical usage and power consumption by 55%. DTG printing creates a precisely printed design with a high level of detail. The washed away areas allow ink to be pushed through open holes in the mesh with a squeegee onto the garment or product, one color at a time. After that the separation process a separate screen has to be created for each color. Using more than the recommended number of colors slows down the process, though, resulting in higher final prices, since each color used needs its own screen stencil created. Some custom apparel services offer just one or the other, while some offer both DTG and screen printing options depending on the size of your project. Offset vs. Digital Printing. In digital printing, however, the print heads are able to produce any possible color without additional adjustments. The Verdict: Digital printing. This is limited to the number of screen positions that the rotary printer has. With years of t-shirt designing experience, we’ve collected our top tips for optimizing your design for printing. Your design is uploaded to a computer that then prints directly onto your merchandise. When considering digital textile printing, printers are often insecure because they fear it is a high initial investment that is doubtful to be earned back. Although there are 24-color rotary machines, most customers are limited to 12 colors but often reduce to 6 to 8 colors to save costs of screens. Before you set off to create your own t-shirt design, here are the ins and outs of digital printing vs screen printing. Jos Notermans Screen printing involves the process of pushing the ink through a woven mesh stencil onto the fabric. The obvious question is the break-even calculation of both technologies: until what print length the costs of digital are lower than rotary? Digital Textile Printing, You may see the total pricing on different costs undertaken in the printing process, but some fail to show the breakdown on the number of colors in the artwork. But also in which country you are going to print, for example. When the screens are engraved, they have to be installed and registered in the rotary printing machine so all colors match up perfectly. This comparison will lead you in the right direction. Fashion brands are under the pressure to produce a large variety of designs and rapidly respond to changes in trends. Ink in digital printing is applied directly to the print material using either a laser jet or inkjet printer. Here at Bonfire, we use both DTG and screen printing methods. The more meters you print with a particular set of screens, the lower the costs of screens per printed meter. Single-pass Printing, While digital sign printing has increased in popularity, it still cannot match the speed of screen printing, especially as the quantities increase. Changing colors to make another colorway can happen instantly, where in conventional you need to clean out the printing paste in each screen and replace it for the new color. The higher the volume, the lower the cost per print becomes. Although screen printing offers a higher quality print output, digital printing is becoming extremely popular as it entails far less pre-press artwork which makes it far more cost-effective. As rotary printing requires a lot more labour than digital, the labour costs from country to country can significantly influence the cost per meter in rotary. Having master stencils for each layer streamlines the process as more shirts are printed. DTG printers are large and capable of handling all kinds of designs in many colors. Direct-to-garment is down two rounds to one and is looking to change the momentum of … It’s printed on thinner in order to properly capture the details of the design, so it could potentially wear more quickly. You also get a discount if … The ink is pulled across the stencil using a blade or foam tool, producing a single layer of the design with full, saturated color. At Ramp, we use screen printing to print your t-shirts. Digital textile printing helps printers to directly print a new order and have it delivered to the customer in a short time frame. This simple change in the cost formula can make offset printing more expensive than digital printing. Glass Digital Printing. In rotary screen printing, on the contrary, a design has to be adjusted with special separation software to reduce the number of colors. Whether you’re creating custom t-shirts for a creative project, a fundraising campaign, or another reason, understanding the printing process will help you make the best possible decisions. Additionally, the cost and time required to set up each color is not cost effective for small-to-medium-sized, custom orders. This makes screen printed custom shirts a smarter choice for larger fundraising or event purposes, like for 5K running teams or a mission trip fundraising campaign. Nowadays, people like to buy their clothing online and are used to having a lot of different options to choose from. This method is capable of printing large amounts of garments much quicker and more economically than digital printing. PIKE, [The Note] Digital textile printing vs screen printing: how to make a cost comparison. In digital printing, however, the print heads are able to produce any possible color without additional adjustments. Knowing when to choose offset printing or digital printing usually depends on the following factors: Price. During the screen printing process, the image is turned into a stencil or screen. Larger items, such as sweatshirts and hooded sweatshirts, can cost anywhere from $18 to $29 each. Digital Printing vs Screen Printing The question of which method of printing is better has been asked many times over the past few years, and the answer is not cut and dry. Print Cost. For that reason, digital textile printing can be a more cost-friendly option for printing companies that work with very colorful designs and many color ways per design. But with screen printing, there are typically cost savings built in as you print more t-shirts! But what’s the difference between these two t-shirt printing methods? When making a cost comparison between rotary screen and digital printing, the initial investment is often the only parameter besides the price of inks that is taken into account. This method of printing involves the use of mesh stencils. Screen Printing is ideal for bulk orders that are approximately 25 or more of the same design. Although there is no hard rule in our operation, a run of 1,500 pieces is usually the “break even” point between offset and digital printing. Cost of Silk Screen vs. DTG Printing. Since these t-shirt printing methods are so different, there are naturally a few pros and cons to each. No matter how many shirts you need or what your design looks like, we’ve got the tools to offer you the best quality and price for your custom apparel! Screen printing as a production method quickly overtakes Digital Printing in cost per print. This process creates a high level of vibranc… Each color used in the design is printed separately with its own screen. Small orders can be equally impractical for screen printing. Next, the printer swipes ink across the screen … On top of that, the fashion industry is changing as a result of digitalization. Here’s how they stack up: Screen printing is most cost-effective for larger batches of shirts. Of course, these costs are then also dependent on the meters of fabric you are going to print of a particular design. The larger the screen printing order, the more cost effective it becomes compared to other methods. The ink, while good quality, is not as durable as the ink from screen printing. Related Article: How … This way, fashion brands are able to meet their customer’s demands and will therefore be more willingly to collaborate with digital printing companies instead of conventional ones. This enables printers to keep up with fast-fashion demands for shorter lead times and acceleration of the time-to-market. Screen printing can bring to life designs that have minimal detail or amount of colors within the artwork… The costs involved are minimal and the set up time in very less. The DTG printing method is precise and produces high-quality results, but the ink is not as deeply soaked into the fabric as with other methods like screen printing. This means that when printing a design that consists of more colors no additional costs are made. For each extra color you want to use in rotary, a new screen has to be engraved. When you want to produce brochures, flyers, books, newsletters, posters, and other marketing material, your first step is … There are so many variations between each customer order that it's difficult to qualify which printer is the cheapest. With years of experience, Jos can tell you all about the basics of textile printing as well as the latest innovations that help you grow your business. Another valuable parameter in a cost comparison is the batch length that you expect to print with the specific technology. Heat transfer printing is very convenient and the level of detail is better than screen print. DTG printing leaves a single layer of ink to create your final design, while screen printing produces several layers. Custom School Shirts: Design School Spirit Tees in 5 Steps, The Art of a 1-Color T-Shirt Design: How a Single Color Design Can Be Anything But Ordinary, Orders of 11-50 shirts (depending on the artwork). A heat press makes sense if you are looking to create a t-shirt line for an apparel company, as it can be more cost effective than screen printing small batches. Simpler, stylized designs with graphics or text in a handful of colors are great for screen printing, while DTG printing can handle more elaborate designs in more colors, usually on light-colored fabric. Screen printing and DTG (direct to garment) printing are two common ways to print custom t-shirts. As pointed out before, it heavily depends on the number of colors you want to print, the number of color ways and the number of printed meters per color way. The number of colors and the print length are the main direct costs parameters which are essential in a cost comparison of digital and rotary screen printing. So, you have a flat cost before you print even one sheet of paper. Again, both can be great choices, but it depends entirely on the specifics of your project. Since no screens have to be engraved, lead times can be shortened considerably. The biggest differences that you should consider when choosing a method fall into two general categories — design and cost. A digital file of a design can be loaded into the digital printing machine in a matter of minutes after which it can directly be printed on fabric. They both have their pros and cons. New research in digital printing is focused on increasing color depth and colorfastness. This break-even point depends on different parameters, mainly in the rotary printing process. Then, according to Gherzi, rotary screen printing is a more economical choice. Screen Printing vs Digital Printing. Jos Notermans attempts to answer all your questions regarding textile printing in 'The Note'. Having master stencils for each layer streamlines the process as more shirts are printed. DETAILS. While offset printing is a fantastic way to produce great-looking print projects, many businesses or individuals do not need large runs of 500 or more, and the best solution is digital printing. DTG printing is most cost-effective for small batches of custom printed t-shirts. With years of experience, Jos can tell you all about the basics of textile printing as well as the latest innovations that help you grow your business. We review every design that is uploaded onto our site and work directly with our customers to make sure their design will print just right. Digital textile printing provides printers with the ability to benefit from new business models. A major limitation of screen printing is its maximum capability of four colors. Archer technology, However, to create a realistic image of the costs of a particular printing technology, certain important parameters cannot be left out. High volume is the bread and butter of screen printing. In case you print between the 1000 and 3000 meters of a single design then it heavily depends on your specific situation (see Figure 1, source: Gherzi whitepaper, 2017). The screen is then placed on the fabric. Three core advantages of digital textile printing that have helped other textile printers to address new business units and assure their businesses of a future. DTG printing involves the use of a digital printer to apply ink directly onto the fabric of the apparel you’re customizing. The printer translates the digital image or graphic file onto your blank tee! Because of these additional steps, the rotary screen printing cycle — from design until finalized product — takes up three to six weeks. This is a newer t-shirt printing method that’s gained a lot of popularity in recent years thanks to technological improvements in DTG printers. When you’re screen printing designs, whether it’s with Bonfire or any other company, you’re typically charged for every ink color used. In an independent study, Gherzi identified the three main investment reasons for digital textile printing. Multi-pass Scanning Printing, The reason being, is that you may not know if certain designs will sell , and don’t want to get stuck with 25 … The fundamental differences between each process also translate to differences in final costs. It is simpler and more cost-effective to utilise silk screen printing artists for mass production, rather than digital printing on fabric. Finding a custom t-shirt printing service that can offer the best of both techniques — DTG and more traditional screen printing — will get you the best value in the long run. You can have your finished t-shirt with little or no clean up. Digital printing is newer, whereas silk screen printing is as old as the Chinese Song Dynasty. The stencil process means that set-up costs are a little higher, but it also makes screen printing more efficient for large orders of one design. A market study from Smithers Pira, "The Future of Digital versus Analogue Printing to 2020," outlines the key trends in digital printing compared with that of analog printing… Then it’s time to discover precisely how this transition can make your business grow. Digital printing works like a big inkjet printer for products. Digital printing is a fresh and innovative solution that offers more flexibility than screen printing on glass. Textile Printing, Digital textile printing can effectively help printers to reduce their carbon footprint and improve their green image. Screen printing is the more traditional technique that involves pushing the ink onto the fabric through a stencil, while direct to garment is a newer method that uses a printer to apply the ink to the shirt. So, if you design a shirt using only one, Where the world goes for premium custom shirts, This makes screen printed custom shirts a smarter choice for larger fundraising or event purposes, like for. This is typically done using design software like Photoshop or Illustrator. For example, extremely high-volume runs - 25,000 decals or 10,000 posters - screen printing is clearly the more cost-effective option. Most importantly, DTG enables order fulfillment on-demand with no upfront cost, while screen … We’ll answer these four most common questions: If you’ve never printed your own custom shirts before, follow these best practices and study up on the different ways your shirts can be produced. By contrast, dye sublimation is time consuming, expensive and highly impractical for large orders. Below, you’ll find both the environmental impact of rotary screen printing (Figure 3) as well as digital textile printing reviewed from cradle to gate, so the production phase of the consumable (Figure 4, source: internal study SPGPrints, 2015). Sometimes to get […] The rest of the substance is then washed away. DTG printing typically does not offer bulk savings the way that screen printing does. This process means that screen printing is better suited to certain kinds of t-shirt designs. It is tough to compare screen printing vs digital printing when each method offers exclusive, worthwhile benefits. Our production team handles each, The Bonfire Design Team works every day to make sure that the vision you have for your t-shirt comes to life in an amazing way! An additional screen is required for each new colour with screen printing which means any additional colours will cost you. JAVELIN, DTG uses a printer to spray the ink into a garment, while screen printing layers the ink on top of the fabric. Plus, digital printing allows us to offer custom tees with no minimum order requirement, unlike screen printing, which has a 12-piece minimum because of its extensive prep time. But with screen printing, there are typically cost savings built in as you print more t-shirts! Each separated color is exposed to individual screens. That’s why we’re able to offer you custom t-shirts for any project at cost and with no order minimums. When considering digital textile printing, printers are often insecure because they fear it is a high initial investment that is doubtful to be earned back.When making a cost comparison between rotary screen and digital printing, the initial investment is often the only parameter besides the price of inks that is taken into account. How much does Screen Printing CostMost printers and screen-printing companies will readily offer a table complete with a price guide on a list. Because of the flexibility of digital textile printing, fashion brands can decide to have small batches of a certain design printed and place repeat orders when that product is selling well. From automation vs manual printing, DTG vs screen printing, or water based ink vs plastisol ink, screen printing shops have to be ready to make these decisions on a daily basis. Understanding the differences between the two methods will help you to better determine exactly what you need from a partner as you get started with your custom t-shirt project! The number of colors used won’t seriously affect the final price. Although digital printing is more costly than rotary screen printing, industry experts argue that digital printing’s efficiencies ultimately make it a more cost-effective option on shorter runs. This has a few important effects, particularly on how you use color in your design: This means that certain types of t-shirt designs are better suited to each method. The scope of your custom t-shirt printing project should be a consideration as you choose a printing service to handle it. One printing method is not “better" than the other, but each one has their pros and cons depending on the type of print job. When should you use one versus the other? For starters, a silkscreen run requires an extensive setup process; this is why we have a 25-shirt minimum order. As a more labor-intensive process, screen printing produces beautiful, saturated colors and a distinctive, authentic appearance. When produced by a professional using the right equipment, either printing process will result in a high-quality t-shirt, but a few important differences still come into play depending on your design. DTG Costs. hbspt.cta._relativeUrls=true;hbspt.cta.load(2131785, '0a4b1477-1886-41cc-a8d1-0b337d52c70f', {}); Another positive driver in favor of digital textile printing is the acceleration of the printing process. Screen printing and digital printing are two different printing processes. What’s the difference between DTG and screen printing? It explains how all parameters can influence your overall printing costs. How much does screen printing cost? DTG and screen printing yield fine quality prints, but they differ in method and cost. When making a cost comparison between rotary screen and digital printing, the number of colors in use in rotary have to be taken into account. Although, it is difficult to quantify these indirect costs in monetary values, they do have a great influence on the way digital textile printing can help you either save costs or attract new business. This break-even point depends on different parameters, mainly in the rotary printing process. If you print more color ways with the same set of screens, the costs are divided over more printed meters. The most important one is printing what you’ve already sold instead trying to sell what you already printed. Update your browser to display this website correctly. In an independent study conducted by Gherzi (. The cost formula for offset pricing: Setup + Plates + Print Cost (ink & labor) + Paper Cost + Bindery + Delivery. Printed apparel that features simple designs is the best choice for this printing method and will increase production time. The number of colors used won’t seriously affect the final price. Let’s go over digital printing vs screen printing and what the difference is. Digital printing inks, Digital Printing, DTG printing is more cost-effective for smaller shirt orders. Depending on the specifics of your custom printing project, one will likely be a better choice than the other. However, large batches will use more ink and time — the printer can only handle one shirt at a time — resulting in higher prices. DTG printing is most cost-effective for small batches of custom printed t-shirts. By following this guide, you’ll create a design, The best way to make the highest profit per shirt that you can is by keeping your production costs low. If you choose a DTG only service, your cost per shirt does not drop as you purchase more, whereas you typically will pay less per shirt as quantities increase when screen printing. This means your design must first be broken down into different layers by color. Sustainability is increasingly becoming a more important issue among textile printers. Find a full overview of all indirect cost drivers for digital textile printing in Figure 2, as listed in a recent study by Gherzi. This estimate is a rough estimate: the exact break-even point is dependent on each specific printing company and for instance also depending on the country you are printing in. On top of that, you need to take the number of colorways into account. Next, a woven screen stencil is used to apply a single color of ink at a time — one stencil per color used in the shirt’s design. Jos Notermans attempts to answer all your questions regarding textile printing in 'The Note'. In this article, I explain how to effectively compare digital printing and screen printing based on Total Cost of Ownership. If you’re looking to design and print your own custom t-shirts, you’ve likely encountered these two terms — DTG printing and screen printing. However, there are various indirect costs that — in order to get a realistic idea of the total price tag of a printing technology — have to be taken into account. Screen Printing vs Digital Printing. Water-based ink is applied in a single layer that quickly absorbs into the shirt’s fibers. This means that when printing a design that consists of more colors no additional costs are made. We’ve previously written about what high quality screen printing is (and why we have thousands of happy customers through using it), but there’s another type of printing that you may have heard of called Digital Printing (which is also known as Direct To Garment, or DTG). Screen printing is a more traditional t-shirt customization method in which each color in a design is separated and burned to individual fine-mesh screens. Rotary screen printing, Ideally, this means that in the future discount sales are no longer necessary. The prices for silk screen printing versus DTG printing can vary. Gherzi estimated that in general when printing less than 1200 meters of a certain design digital textile printing is cheaper than rotary screen printing. Both screen printing and direct to garment (DTG) are methods of printing custom designs onto fabrics. Screen Printing. Do you print more than 3000 meters of a certain design? Below, I’ll specify the most important indirect costs in more detail. DTG printing works like the inkjet printer in your home office. It’s a craft that skilled printers have perfected over the years to produce great-looking, durable clothing. For more information, context, and ideas on working with custom apparel, be sure to explore some additional resources: At Bonfire, our goal is to make you the hero of your community by providing amazing t-shirts and rocking designs! Screen printing versus digital printing. Needless to say, the more colors that are used in a particular design, the higher the operational costs. 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